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TW201336447A - 裝飾板 - Google Patents

裝飾板 Download PDF

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Publication number
TW201336447A
TW201336447A TW101137668A TW101137668A TW201336447A TW 201336447 A TW201336447 A TW 201336447A TW 101137668 A TW101137668 A TW 101137668A TW 101137668 A TW101137668 A TW 101137668A TW 201336447 A TW201336447 A TW 201336447A
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TW
Taiwan
Prior art keywords
resin
decorative
weight
prepreg
slurry
Prior art date
Application number
TW101137668A
Other languages
English (en)
Other versions
TWI559876B (en
Inventor
Masataka Yasui
Kazuki Kouyama
Tomoya Ogino
Original Assignee
Aica Kogyo Co Ltd
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Publication date
Application filed by Aica Kogyo Co Ltd filed Critical Aica Kogyo Co Ltd
Publication of TW201336447A publication Critical patent/TW201336447A/zh
Application granted granted Critical
Publication of TWI559876B publication Critical patent/TWI559876B/zh

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Classifications

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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
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    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Textile Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

一種裝飾板，其係將包含(a)黏合劑成分及(b)吸熱性金屬氫氧化物之預浸體2，與含浸熱硬化性樹脂的裝飾紙1進行積層成為一體之裝飾板5，上述(a)黏合劑成分為(a1)至少一種選自玻璃轉移溫度Tg超過0℃之丙烯酸樹脂、玻璃轉移溫度Tg超過0℃之氯乙烯樹脂、丙烯酸聚胺酯、及水性聚胺酯所成群組中之熱塑性樹脂，及(a2)熱硬化性樹脂；且(a1)與(a2)之調配比率以固形分比為1：0至0.5。

Description

裝飾板 [參照之相關申請案]
本案係主張於2011年10月13日向日本特許廳提出申請之日本國專利申請第2011-225419號之優先權，並於本案援用日本國專利申請第2011-225419號之全部內容。
本發明係關於裝飾板。
以往已知有熱硬化性樹脂裝飾板。而熱硬化性樹脂裝飾板之中，以特別適合於JIS K 6902的「熱硬化性樹脂高壓裝飾板試驗方法」之三聚氰胺(melamine)裝飾板來說，因為其耐熱性、耐衝擊性、耐損耗性、及尺寸安定性為優異，故被廣泛使用於住宅機器、內裝材(例如頂板、吧檯板(counter)等)等。
近年來，已知以無機纖維不織布取代牛皮紙(kraft paper)作為構成芯層之纖維質基材使用，同時使用調配有由熱硬化性樹脂製成的黏合劑成分與無機填充材之漿液(專利文獻1)。此外，亦揭示有使用經含浸包含熱硬化性樹脂、合成樹脂乳劑、和橡膠乳膠(rubber latex)等熱塑性樹脂之漿液的預浸體而製造不易燃性裝飾板之技術(專利文 獻2、3、4)。
[先前技術文獻]
[專利文獻]
專利文獻1：日本特開2008-290444號公報
專利文獻2：日本特開2005-103769號公報
專利文獻3：日本特開2005-199532號公報
專利文獻4：日本特開平3-253342號公報
然而，以往之不易燃性裝飾板之板厚為厚度3mm左右，若接合加工於書桌、餐桌的頂板，則會因為有顯眼的木材切口面而無一體感。此外，由於以往之不易燃性裝飾板既厚且重，故在家具加工步驟中，較板厚為0.8至1.6mm的一般三聚氰胺裝飾板難以作業。而本發明之一著眼處即係解決以上所述問題。
本發明之裝飾板，係：將包含(a)黏合劑成分及(b)吸熱性金屬氫氧化物之預浸體(prepreg)，與含浸熱硬化性樹脂的裝飾紙進行積層成為一體者；上述(a)黏合劑成分為(a1)至少一種選自玻璃轉移溫度Tg超過0℃之丙烯酸樹脂、玻璃轉移溫度Tg超過0℃之氯乙烯樹脂、丙烯酸聚胺酯、及水性聚胺酯樹脂所成群組中之熱塑性樹脂，及(a2)熱硬化性樹脂，而(a1)與(a2)之調配比率以固形分比為1：0至0.5。
本發明裝飾板之板厚雖薄(例如為0.6至0.8mm)仍具有不易燃性。此外，本發明之裝飾板係容易加工。翹曲亦小，而容易進行處理。
1‧‧‧含浸三聚氰胺樹脂的裝飾紙
2‧‧‧預浸體
3‧‧‧含浸三聚氰胺樹脂的平衡紙
5,5’‧‧‧不易燃性裝飾板
第1圖為表示不易燃性裝飾板5之結構的剖面圖。
第2圖為表示不易燃性裝飾板5’之結構的剖面圖。
本發明中，(a1)熱塑性樹脂與(a2)熱硬化性樹脂之調配比率以固形分比(重量比)為1：0至0.5。藉由於此範圍內，提升裝飾板之可撓性。
(a1)熱塑性樹脂係至少一種選自玻璃轉移溫度Tg超過0℃之丙烯酸樹脂、玻璃轉移溫度Tg超過0℃之氯乙烯樹脂、丙烯酸聚胺酯、及水性聚胺酯所成群組中者。丙烯酸聚胺酯、及水性聚胺酯之玻璃轉移溫度Tg並無特別限定。
此外，若使用平均粒徑150至300nm的丙烯酸樹脂乳劑作為(a1)熱塑性樹脂，則可進一步提升預浸體的接著力，及裝飾板之彎曲加工性及平滑性。提升平滑性的原因可推測是因為丙烯酸樹脂乳劑係微粒子之故。又，平均粒徑係使用雷射光繞射/散射粒徑測定裝置(大塚電子股份有限公司ELS-8000)，依照射雷射時檢測出之散射光所計算之值。
作為前述(a2)熱硬化性樹脂，例如可列舉三聚氰胺-甲醛(melamine-formaldehyde)樹脂、酚-甲醛樹脂、不飽和聚酯樹脂等。該等之中若使用玻璃轉移溫度超過0℃之丙烯 酸樹脂，則可進一步提升彎曲性、密合性、成形性。(a2)熱硬化性樹脂為任意成分，亦可不調配。
(b)吸熱性金屬氫氧化物由於含有結晶水，在高溫時會分解、吸熱、並放出結合水，故可提升本發明裝飾板之不易燃性。吸熱性金屬氫氧化物係例如可列舉氫氧化鋁、氫氧化鎂、氫氧化鈣等。
(b)吸熱性金屬氫氧化物係例如可與(a)黏合劑成分一同作為漿液之調配成分。將該漿液含浸纖維質基材，即可製造預浸體。吸熱性金屬氫氧化物的平均粒徑可於例如1至50μm之範圍內。該平均粒徑係由以雷射繞射/散射法(微型追蹤(micro track)法)檢測出之粒度分布(體積分布)算出之算數平均粒徑。藉由吸熱性金屬氫氧化物之平均粒徑為上述之範圍內，提升漿液中之(b)吸熱性金屬氫氧化物的分散性，並提升漿液對纖維質基材之含浸性。此外，藉由吸熱性金屬氫氧化物之平均粒徑為上述之範圍內，將裝飾板表面製成平滑。
前述預浸體除了包含(b)吸熱性金屬氫氧化物以外，亦可包含例如非含水無機填充材。非含水無機填充材例如可列舉碳酸鈣、碳酸鎂、碳酸鋅等碳酸鹽；氧化矽(silica)、滑石、飛灰(fly ash)等。非含水無機填充材之平均粒徑(由以雷射繞射/散射法(微型追蹤法)檢測出之粒度分布(體積分布)算出之算數平均粒徑)，係可於例如0.05至20μm之範圍內。此時，漿液對纖維質基材之含浸適性會進一步提升。
非含水無機填充材中，尤其是可選擇碳酸鹽(例如碳酸鈣)。在此情形下，裝飾板的製造步驟之作業性、切削性會進一步提升。碳酸鈣係可使用例如重質碳酸鈣、輕質碳酸鈣(沈澱碳酸鈣(precipitated calcium carbonate))等。碳酸鈣之平均粒徑係例如可為0.05至10μm，更佳為1至5μm。藉由於0.05μm以上，使漿液中之碳酸鈣不易發生凝結，而提升漿液對纖維質基材之含浸性。此外，藉由於10μm以下，使裝飾板表面變得更為平滑，而使外觀變佳。
又，輕質碳酸鈣意指石灰石經燒成並以化學方式製造的碳酸鈣，重質碳酸鈣係意指將白色結晶質石灰石經乾式或濕式粉碎所製造的細粉碳酸鈣。
預浸體所包含之全部無機填充材中，(b)吸熱性金屬氫氧化物所佔之調配比率，係例如可為50至100重量%。在此情形下，裝飾板之不易燃性會進一步提升。
本發明之裝飾板中，預浸體係例如可包含(c)矽烷偶合劑。就JIS K-6902的「熱硬化性樹脂高壓裝飾板試驗方法」之耐煮沸性而言，較之不包含(c)矽烷偶合劑的情形，在包含(c)矽烷偶合劑的情形下，重量增加率變得更小，此外，預浸體與含浸熱硬化性樹脂的裝飾紙之密合性會進一步提升。
(c)成分之調配比率，係例如可為(a)+(b)+(c)的全部成分中之0.7至0.9重量%。此時，就JIS K-6902的「熱硬化性樹脂高壓裝飾板試驗方法」之耐煮沸性而言，重量增加率變得更小，此外，預浸體與含浸熱硬化性樹脂的裝飾紙 之密合性會進一步提升。
矽烷偶合劑係可列舉例如3-(甲基)丙烯醯氧基丙基三甲氧基矽烷、3-(甲基)丙烯醯氧基丙基三乙氧基矽烷等含有(甲基)丙烯醯氧基之矽烷；乙烯三甲氧基矽烷、乙烯三乙氧基矽烷等含有乙烯基之矽烷；3-環氧丙氧基丙基三甲氧基矽烷、3-環氧丙氧基丙基三乙氧基矽烷等含有環氧基之矽烷；對苯乙烯基三甲氧基矽烷等含有苯乙烯基之矽烷；3-胺基丙基三甲氧基矽烷、3-胺基丙基三乙氧基矽烷等含有胺基之矽烷；3-巰基丙基三甲氧基矽烷等含有巰基之矽烷等。尤其，若使用含有環氧基之矽烷或含有胺基之矽烷，則預浸體之交聯密度會進一步提升。
全部組成物(a+b+c)中之(a)黏合劑成分的比率，以固形份計之，係例如可為9至15重量%。藉由為15重量%以下，不易燃性會進一步提升，同時在熱壓成形時將不易發生合成樹脂滲出之情形。此外，藉由為9重量%以上，預浸體彼此間之密合度會進一步提升，同時更易於調控漿液對纖維質基材之含浸量。
本發明裝飾板之預浸體，係可藉由將包含(a)黏合劑成分及(b)吸熱性金屬氫氧化物之漿液含浸纖維質基材之方式製造。該纖維質基材例如可列舉有機纖維基材及無機纖維基材等。
有機纖維基材可列舉例如：聚乙烯、聚丙烯、維尼綸(vinylon)、聚氯乙烯、聚偏二氯乙烯、聚丙烯腈、聚醯胺、聚酯、聚胺酯等；該等之改性物；包含乙烯-乙酸乙烯酯共 聚物等所代表之各種共聚物的纖維；該等之混合物、及包含該等之聚合物的複合纖維等。
無機纖維基材可列舉例如：包含玻璃纖維、岩絨(rock wool)、碳纖維等無機纖維之不織布、織品等。無機纖維基材之基重(basis weight)係例如可於10至200g/m2之範圍內。使用無機纖維基材時，裝飾板之不易燃性係較使用有機纖維基材時更為提升。無機纖維基材之中，尤以使用玻璃纖維不織布時，耐熱性、防火性、漿液之含浸性會進一步提升。
漿液對纖維質基材之固形分含浸率(%)，以算式1所示之計算方法而言，係以700至1200%之範圍內為佳。藉由為1200%以下，自預浸體脫落之漿液的固形分會減少，預浸體變得易於處理。藉由為700%以上，會變得不易發生預浸體之層間剝離。
就本發明之裝飾板而言，係可將裝飾層形成在包含已於纖維質基材含浸漿液之預浸體的芯層之至少一面。形成裝飾層的方法係例如可列舉：施予塗裝之方法、使用含浸樹脂的裝飾紙之方法、使用轉印箔轉印裝飾層之方法等。當使用含浸樹脂的裝飾紙時，裝飾板之生產性、芯層與裝飾層之密合性、及裝飾層之耐損耗性會進一步提升。
使用含浸樹脂的裝飾紙之方法，例如：首先，將以熱硬化性樹脂為主成分的樹脂液含浸熱硬化性樹脂裝飾板用底紙，其次，將經乾燥之含浸樹脂的裝飾紙進行積層，並進行熱壓成形之方法。熱壓成形可使用例如平板沖壓式、連續沖壓式等的沖壓機。
含浸樹脂的裝飾紙係例如可以下述方式製造：將包含胺基-甲醛樹脂、苯二甲酸二烯丙酯樹脂、不飽和聚酯樹脂等熱硬化性樹脂之樹脂液，以算式1所示之含浸率成為80至300%之方式含浸熱硬化性樹脂裝飾板用之30至140g/m2的裝飾紙。含浸樹脂的裝飾紙之中，係以含浸胺基-甲醛樹脂的裝飾紙的耐熱性、耐損耗性更為優異。
本發明之裝飾板係可在其之單面或雙面形成裝飾層。僅於單面形成裝飾層(例如由含浸樹脂的裝飾紙構成裝飾層)時，可於另一面配置平衡紙(balance paper)。配置有平衡紙時，係可進一步抑制裝飾板之翹曲或破損。
平衡紙係例如可列舉：對於基重18至40g/m2之裝飾板用表面紙(surface paper)，將以熱硬化性樹脂(例如三聚氰胺樹脂、脲樹脂、胍胺樹脂、苯二甲酸二烯丙酯樹脂)為主成分之經水、有機溶劑稀釋而調整黏度之樹脂液，以依算式1之計算方法為260至320%之方式含浸，並經乾燥之含浸樹脂的平衡紙。
(實施例1)
(1)漿液之製造
製造包含以下成分之漿液。
玻璃轉移溫度Tg為47℃，以丙烯酸乙酯與甲基丙烯酸甲酯作為主要單體之丙烯酸樹脂乳劑(型號AXN-150，AICA工業股份有限公司製，平均粒徑225nm)：36重量份(固形分)。
平均粒徑8μm之氫氧化鋁(吸熱性金屬氫氧化物)：200重量份
平均粒徑1μm之重質碳酸鈣(非含水無機填充材)：40重量份
又，前述丙烯酸樹脂乳劑係(a1)成分之一實施型態。
(2)預浸體之製造
對於50g/m2之玻璃纖維不織布(纖維質基材)，以算式1所定義之計算方法使含浸率成為800%之方式，含浸前述(1)所製造之漿液，並進行乾燥，製造預浸體。
(3)含浸三聚氰胺樹脂的裝飾紙之製造
對於基重100g/m2之白色熱硬化性樹脂裝飾板用裝飾紙，以算式1所定義之計算方法使含浸率成為130%之方式，含浸以三聚氰胺-甲醛樹脂為主成分之樹脂液，並進行乾燥，製造含浸三聚氰胺樹脂的裝飾紙。
(4)含浸三聚氰胺樹脂的平衡紙之製造
對於基重23g/m2之熱硬化性樹脂裝飾板用的表面紙，以算式1所定義之計算方法使含浸率成為280%之方式，含浸以三聚氰胺-甲醛樹脂為主成分之樹脂液，並進行乾燥，製造含浸三聚氰胺樹脂的平衡紙。
(5)不易燃性裝飾板之製造
依下列順序，將前述(4)所製造之含浸三聚氰胺樹脂的裝飾紙1枚、前述(2)所製造之預浸體2枚、及前述(3)所製造之含浸三聚氰胺樹脂的平衡紙1枚進行積層，並使用平面加工板，以130℃、70kg/cm2、60分鐘之條件熱壓成形為一體，製造不易燃性裝飾板。依第1圖所示方式製造的不易燃性裝飾板5，係具有積層1枚含浸三聚氰胺樹脂的裝飾紙1、2枚預浸體2、及1枚含浸三聚氰胺樹脂的平衡紙3的結構。
又，於表1至表3，係表示本實施例、後述各實施例及比較例所製造之不易燃性裝飾板的組成。組成的單位為重量份。
(實施例2)
基本上係以與前述實施例1相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，丙烯酸樹脂乳劑之調配量為30重量份。
(實施例3)
基本上係以與前述實施例1相同之操作製造不易燃性 裝飾板。惟在漿液之製造方面，係加入了1種含有環氧基之矽烷的3-環氧丙氧基丙基三甲氧基矽烷((c)矽烷偶合劑)2.4重量份。
(實施例4)
基本上係以與前述實施例3相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，丙烯酸樹脂乳劑之調配量為26重量份，此外，3-環氧丙氧基丙基三甲氧基矽烷((c)矽烷偶合劑)之調配量為2.2重量份。
(實施例5)
基本上係以與前述實施例3相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，丙烯酸樹脂乳劑之調配量為32重量份，此外，3-環氧丙氧基丙基三甲氧基矽烷((c)矽烷偶合劑)之調配量為2.2重量份。
(實施例6)
基本上係以與前述實施例3相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，丙烯酸樹脂乳劑之調配量為26重量份，此外，3-環氧丙氧基丙基三甲氧基矽烷((c)矽烷偶合劑)之調配量為1.9重量份。
(實施例7)
基本上係以與前述實施例3相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，丙烯酸樹脂乳劑之調配量為34重量份，氫氧化鋁之調配量為120重量份，重質碳酸鈣之調配量為120重量份，3-環氧丙氧基丙基三甲氧基矽烷((c)矽烷偶合劑)之調配量為2.2重量份。
(實施例8)
基本上係以與前述實施例3相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，丙烯酸樹脂乳劑之調配量為34重量份，氫氧化鋁之調配量為240重量份，3-環氧丙氧基丙基三甲氧基矽烷((c)矽烷偶合劑)之調配量為2.2重量份。
(實施例9)
基本上係以與前述實施例3相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，3-環氧丙氧基丙基三甲氧基矽烷((c)矽烷偶合劑)之調配量為2.2重量份。此外，不使用含浸三聚氰胺樹脂的平衡紙而製造不易燃性裝飾板。如第2圖所示，所製造之不易燃性裝飾板5’係具有積層有1枚含浸三聚氰胺樹脂的裝飾紙1、及2枚預浸體2之結構。
相較於前述實施例1至8所製造之不易燃性裝飾板，本實施例所製造之不易燃性裝飾板係彎曲強度稍弱，翹曲稍大。
(實施例10)
基本上係以與前述實施例3相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係以2.2重量份之3-(2-胺基乙基)胺基丙基三甲氧基矽烷(SH-6020，商品名稱，東麗道康寧股份有限公司製)取代3-環氧丙氧基丙基三甲氧基矽烷。3-(2-胺基乙基)胺基丙基三甲氧基矽烷係(c)矽烷偶合劑之一實施型態。
(實施例11)
基本上係以與前述實施例3相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用同量之丙烯酸聚胺酯乳劑(WEM-3008，商品名稱，大成精化股份有限公司製)取代丙烯酸樹脂乳劑(型號AXN-150，AICA工業股份有限公司製，平均粒徑225nm)，此外，3-環氧丙氧基丙基三甲氧基矽烷之調配量為2.2重量份。
(實施例12)
基本上係以與前述實施例11相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用同量之使高分子量的熱塑性聚胺酯樹脂安定地分散於水中之非離子性的水性聚胺酯樹脂(HYDRAN(註冊商標)WLI-602，商品名稱，DIC股份有限公司製)取代丙烯酸聚胺酯乳劑(WEM-3008，商品名稱，大成精化股份有限公司製)。
(實施例13)
基本上係以與前述實施例11相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用同量之以氯乙烯聚合物為主成分的氯乙烯系水溶液(Vinyblan(註冊商標)711，玻璃轉移溫度30℃，日信化學股份有限公司製)取代丙烯酸聚胺酯乳劑(WEM-3008，商品名稱，大成精化股份有限公司製)。
(實施例14)
基本上係以與前述實施例4相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，丙烯酸樹脂乳劑之調配量為24重量份，此外，調配三聚氰胺-甲醛樹脂12重量份。
(比較例1) (漿液之製造)
製造包含以下成分之漿液。
酚-甲醛樹脂：36重量份(固形分)
平均粒徑8μm之氫氧化鋁：200重量份
平均粒徑1μm之重質碳酸鈣：40重量份
3-環氧丙氧基丙基三甲氧基矽烷：2.2重量份
(2)預浸體之製造
於50g/m2的玻璃纖維不織布(纖維質基材)，以算式1所定義之計算方法使含浸率成為760%之方式，含浸前述(1)所製造的漿液，並進行乾燥，製造預浸體。
(3)含浸三聚氰胺樹脂的裝飾紙之製造
以與前述實施例1相同之操作製造含浸三聚氰胺樹脂的裝飾紙。
(4)含浸三聚氰胺樹脂的平衡紙之製造
以與前述實施例1相同之操作製造含浸三聚氰胺樹脂的平衡紙。
(5)不易燃性裝飾板之製造
依下列順序，將前述(4)所製造之含浸三聚氰胺樹脂的平衡紙1枚、前述(2)所製造之預浸體2枚、及前述(3)所製造之含浸三聚氰胺樹脂的裝飾紙1枚進行積層，並使用平面加工板，以130℃、70kg/cm2、60分鐘之條件熱壓成形為一體，製造不易燃性裝飾板。
(比較例2)
基本上係以與前述比較例1相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用同量之三聚氰胺-甲醛樹脂取代酚-甲醛樹脂。
(比較例3)
基本上係以與前述比較例1相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用熱塑性樹脂之玻璃轉移溫度(Tg)47℃的丙烯酸樹脂乳劑(型號AXN-150，AICA工業股份有限公司製，平均粒徑225nm)18重量份(固形分)、與三聚氰胺-甲醛樹脂18重量份(固形分)，以取代酚-甲醛樹脂。
(比較例4)
基本上係以與前述比較例1相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用熱塑性樹脂之玻璃轉移溫度(Tg)47℃的丙烯酸樹脂乳劑(型號AXN-150，AICA工業股份有限公司製，平均粒徑225nm)12重量份(固形分)、與三聚氰胺-甲醛樹脂24重量份(固形分)，以取代酚-甲醛樹脂。
(比較例5)
基本上係以與前述比較例1相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用熱塑性樹脂之玻璃轉移溫度(Tg)47℃的丙烯酸樹脂乳劑(型號AXN-150，AICA工業股份有限公司製，平均粒徑225nm)18重量份(固形分)、與酚-甲醛樹脂18重量份(固形分)，以取代酚-甲醛樹脂。
本比較例之丙烯酸樹脂乳劑與酚-甲醛樹脂的相溶性差，未能製造不易燃性裝飾板。
(比較例6)
基本上係以與前述實施例1相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用酚-甲醛樹脂11.5重量份(固形分)、與三聚氰胺-甲醛樹脂9.5重量份(固形分)，以取代丙烯酸樹脂乳劑。
(比較例7)
基本上係以與前述實施例1相同之操作製造不易燃性裝飾板。惟在漿液之製造方面，係使用玻璃轉移溫度-21℃之丙烯酸樹脂乳劑(型號CMX-43，AICA工業股份有限公司製)36重量份(固形分)，以取代玻璃轉移溫度47℃的丙烯酸樹脂乳劑(型號AXN-150，AICA工業股份有限公司製，平均粒徑225nm)。
(比較例8)
將含浸酚-甲醛樹脂的芯紙5枚、含浸三聚氰胺-甲醛樹脂的花紋紙(pattern-paper)1枚進行積層，並以130℃、70kg/cm2、60分鐘之條件進行熱壓成形，得到厚度1.2mm的三聚氰胺裝飾板(公知的三聚氰胺裝飾板)。
<裝飾板之評估>
對各實施例及各比較例之裝飾板進行不易燃性、彎曲強度、彈性模數、尺寸變化率、裝飾板之翹曲、彎曲加工性、及重量增加率之評估試驗。試驗方法係如以下所述。
(i)不易燃性
依照ISO5660，以錐形卡路里計(cone calorimeter)進行試驗20分鐘之發熱性試驗。滿足以下之α至γ全部者評估為○，此外評估為×。
α：總發熱量為8MJ/m2以下
β：最高發熱速度為持續10秒以上且未超過200KW/m2
γ：試驗開始後20分鐘之間，未產生貫穿至表面的龜裂或孔洞。
(ii)彎曲強度
依照JIS K 7171「塑膠-彎曲特性之求法」進行測定。
(iii)彈性模數
依照JIS K 7171「塑膠-彎曲特性之求法」進行測定。
(iv)尺寸變化率
依照JIS K 6902「熱硬化性樹脂高壓裝飾板試驗方法」之尺寸安定性試驗進行測定。
(v)裝飾板之翹曲
將纖維方向為短方向之50mm×300mm的試樣於室溫40℃、溼度30%之環境進行熟成24小時。之後，測定將試樣置於水平面上時從水平面算起的翹曲高度。
(vi)彎曲加工性
將試樣裁切為寬度150mm，以具指定半徑之折彎器以使裝飾板的纖維方向平行於折彎器之方式彎曲加工，並藉由目視確認有無裂痕產生。以不產生裂痕之最小彎曲率作為測定值。
(vii)重量增加率
依照JIS K 6902「熱硬化性樹脂高壓裝飾板試驗方法」之耐煮沸性進行測定。又，標準值為17%以下。
試驗評估結果係示於上述表1至表3。由其結果，可明瞭到實施例1至14之裝飾板的板厚雖薄，卻具不易燃性，而且在彎曲強度、彈性模數、尺寸變化率、裝飾板之翹曲、彎曲加工性、重量增加率的各項目係屬優異，容易加工，便於處理。
相對於此，比較例1至8之裝飾板係其中至少一評估項目低劣。特別是比較例1至4之裝飾板的裝飾板之翹曲低劣。並且，比較例6之裝飾板的彎曲加工性低劣。此外，比較例7之裝飾板的彈性模數小而難以進行處理。
1‧‧‧含浸三聚氰胺樹脂的裝飾紙
2‧‧‧預浸體
3‧‧‧含浸三聚氰胺樹脂的平衡紙
5‧‧‧不易燃性裝飾板

Claims (5)

  1. 一種裝飾板，其係將包含(a)黏合劑成分及(b)吸熱性金屬氫氧化物之預浸體(prepreg)，與含浸熱硬化性樹脂的裝飾紙進行積層成為一體者；上述(a)黏合劑成分為(a1)至少一種選自玻璃轉移溫度Tg超過0℃之丙烯酸樹脂、玻璃轉移溫度Tg超過0℃之氯乙烯樹脂、丙烯酸聚胺酯、及水性聚胺酯所成群組中之熱塑性樹脂，及(a2)熱硬化性樹脂，而(a1)與(a2)之調配比率以固形分比為1：0至0.5。
  2. 如申請專利範圍第1項所述之裝飾板，其中，前述預浸體復包含(c)矽烷偶合劑。
  3. 如申請專利範圍第1項或第2項所述之裝飾板，其中，前述(b)吸熱性金屬氫氧化物為氫氧化鋁。
  4. 如申請專利範圍第1項至第3項中任一項所述之裝飾板，其中，前述熱塑性樹脂為丙烯酸樹脂乳劑。
  5. 如申請專利範圍第1項至第4項中任一項所述之裝飾板，其中，前述預浸體係以玻璃纖維不織布為基材。
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US10449748B2 (en) 2019-10-22
US20140242871A1 (en) 2014-08-28
MY163825A (en) 2017-10-31
CN103874576B (zh) 2016-08-17
SG11201401304TA (en) 2014-10-30
AU2012321703A1 (en) 2014-05-01
EP2767392A4 (en) 2015-06-17
HK1198974A1 (zh) 2015-06-19
EP2767392B1 (en) 2019-12-18

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